Door assembly



NOV. 19,1968 GROAT 3,411,240

DOOR ASSEMBLY Filed April 4, 1967 s I 22 Y H 44?; P19! I Y INVENTOR. Manskal/ 0. 6mm

dufw Af/amgge United States Patent 3,411,240 DOOR ASSEMBLY Marshall 0. Groat, Fort Payne, Ala., assignor to Kingsberry Homes Corporation, a corporation of Delaware Filed Apr. 4, 1967, Ser. No. 628,432 3 Claims. (Cl. 49380) ABSTRACT OF THE DISCLOSURE A door assembly having a pair of door frames connected along their outer edges to door casings with the inner sides of the door frames facing each other and connected by connector members to each other and to jamb studs. A door is hingedly connected along one edge to one side of one door frame and the opposite edge of the door is retained adjacent the other side of said one door frame by a keeper and gauge member. A trans-verse member connects the lower ends of the door frames and the door is held in spaced relation to the transverse member by a door support.

Background of the invention Heretofore in the art to which my invention relates, difiiculties have been encountered in erecting door assemblies due to the fact that no effective means have been provided to hold the door in proper relation to its various component parts during shipping and installation. The prevalent method of holding a door in fixed relation with its frame is to drive nails through one of the frames into the door. While these nails retain the door in place during shipping and handling up to the point of installation, the nails must be removed before installation. Not only are such nails not accessible during installation, but they mar the edge of the doors. Difficulties have also been encountered in attatching casing members to the door frame members. Small nails driven perpendicular through the thin edge of conventional casing members have very little holding power when set below the surface of the casing so as to be covered with putty and then painted. It is a common practice to use staples across the grain and drive them below the surface. While such staples hold the casing members in place, countersinking the staples leave bad scars and indentations which are difficult to repair in order to prevent showing after painting or finishing.

Brief summary of invention In accordance with my present invention, I secure door casings to a pair of door frames. The door is hingedly connected along one edge to one side of one door frame and the opposite edge of the door is retained adjacent the other side of its door frame. A transverse member connects the lower ends of the door frames to each other to limit outward movement thereof during shipment and installation and a door spacer is attached to the lower portion of the door in position to engage the transverse member. Improved means is provided for connecting the inner sides of the door frames to each other and to the wall stud at the time of installation whereby the entire door assembly is held in proper position during installation without having to employ one person to hold the structure in place while another secures the various components to each other and to the wall studs. The door and its adjacent component parts are secured fixedly and rigidly to each other during installation whereby one man alone can install the door unit.

Apparatus embodying features of my invention is illustrated in the accompanying drawing, forming a part of this application, in which:

Patented Nov. 19, 1968 FIG. 1 is a side elevational view showing a door assembly made in accordance with my invention;

FIG. 2 is an enlarged, fragmental -view showing the lower righthand corner of the assembly shown in FIG. 1;

FIG. 3 is a sectional view taken generally along the line 33- of FIG. 2; and

FIG. 4 is a fragmental view taken generally along the line 44 of FIG. 3.

Referring now to the drawing for a better understanding of my invention, I show a pair of door casings 10, each comprising a horizontal top casing member 11 and a pair of vertical casing members 12 and 13. The casings 10 are adapted to be positioned at opposite sides of wall studs 14, as shown in FIG. 3. The casing members overlap adjacent edges of wall members 16, as shown in FIG. 3, whereby there is no gap left between the edges of the Wall members 16 and the casing members.

Secured to the inner surface of the casing members 11, 12 and 13 of the door casings 10 are a pair of door frames, commonly called jambs, each comprising a horizontal top frame member 17 and a pair of spaced apart vertical frame members 18 and 19. As shown in FIG. 3, the inner sides of adjacent vertical frame members 18 and 19 face each other and may be spaced from each other, as shown. The frame members 17, 18 and 19 are secured to the casing members 11, 12 and 13, respectively, by driving nail-like members 21 through the frame members into the inner surface of the casing members, as shown in FIG. 3, whereby the inner ends of the nail-like members 21 are in spaced relation to the surface of the casing members. This not only provides a firm connection between the frame members and the casing members but prevents the inner ends of the nail-like member 21 from projecting beyond or distorting the surface of the casing members. To accomplish this, I drive the nail-like member 21 through the door frame members 17, 18 and 19 at an angle of approximately 30 relative to a vertical plane passing through the inner surface of the casing members 10 and the adjacent surfaces of the door frame members. Preferably, the nail-like members 21 are eX- posed at the point of juncture of the door frame members and the casing members, as shown in FIG. 3.

Oppositely disposed recesses 22 and 23 are provided in adjacent vertical frame members 18 and 19, as shown in FIGS. 2 and 3 for receiving a jamb plate 24. The recesses 22 and 23 are sawed at a predetermined depth and the jamb plate 24 is of a predetermined length whereby adjacent vertical frame members 18 and 19 are held in parallel, spaced relation to each other to adjust to the proper distance between the door casings 10 at opposite sides of the wall studs 14. As shown in FIG. 3, opposite ends of the jamb plate 24 engage the recesses 22 and 23 with a tight fit after the door assembly is erected. One end of the jamb plate 24 is provided with laterally projecting anchor members 26 which project outwardly of the plane of the jamb plate to thus firmly anchor that end of the jamb plate 24 to the vertical frame member 19 during shipping and handling. The jamb plate 24 serves as a device to keep the two adjacent frame members in the same related plane one with the other end at the same time allows the two frame members to adjust or move toward or away from one another to accommodate the wall thickness. While wall studs 14 have a standard size,

wall coverings 16 usually vary from /2 inch to inch.

Accordingly, the components of a specific door unit are designed and sized, particularly the width of the frame members, to accommodate wall thicknesses within a definite minimum and maximum limit.

The jamb plate 24 also serves as a device to anchor the adjacent frame members to the wall stud. This anchorage prevents movement of the frame members toward or away from the wall stud. Movement of the adjacent jamb member, after installation, directly toward or away from one another is prevented by the casing being attached to its frame members and the wall stud. The end of the jamb plate having the detent anchor 26 is quite firmly fixed in the one frame member, primarily for shipping. The other end of the jamb plate does not have the detent anchor so that it will be an easy fit at the time of installation.

As shown in FIG. 2, the jamb plate 24 is provided with a centrally disposed opening 27 therethrough for receiving a jamb pin 28 which extends through the opening in position to penetrate the wall stud 14, as shown in FIG. 3. The portion of the jamb pin 28 which penetrates the jamb stud 14 is provided with an outwardly projecting detent 29 which extends outwardly of the surface of the jamb pin 28. The primary purpose of the detent 29 is to allow the jamb pin 28 to be attached to and shipped with the jamb plate 24. To limit inward movement of the jamb pin 28 relative to the jamb plate 24, I provide a laterally projecting detent 31 on the pin 28 in position to engage the side of the jamb plate 24, as shown in FIGS. 2 and 3. Accordingly, upon inserting the jamb plates 24 into the recesses 22 and 23 and then driving the jamb pin 28 into the wall stud 14, the vertical frame members 18 and 19 are firmly connected to each other and to the wall studs 14 at opposite sides of the door. Preferably, the ends of the jamb pins 28 are tapered as at 32 to facilitate driving the pins into the jamb studs 14.

The jamb pin 28 has, in addition to the detent stop 31,

a spring-type stop 30 that reacts when the jamb pin is driven in the wall stud 14 to a depth suflicient to bring the detent stop 31 in contact with the jamb plate 24. When this contact occurs the spring-type detent 30 snaps out and locks the jamb plate between it and detent 31. At this point the pin has been driven to its proper depth into the wall stud.

As shown in FIG. 1, a door 33 is hingedly connected to the vertical frame member 18 of one of the door frames by hinges 34. The opposite edge of the door 33 is retained in place and in spaced relation to the adjacent surface of the vertical frame member 19 adjacent thereto by a combined keeper and gauge member indicated generally at 36. Preferably, the keeper and gauge member is formed of sheet metal or the like and comprises an intermediate portion 37 having a raised head 38 extending substantially the length thereof to provide the proper spacing between the adjacent edge of the door 33 and the vertical frame member 19, as shown in FIG. 3. That is, the bead 38 provides an effective thickness for the intermediate portion 37 which is equal to the desired clearance between the door and the adjacent vertical frame member. Formed integrally with one end of the intermediate portion 37 is an inwardly extending flange 39 which extends alongside the door 33 and generally perpendicular to the intermediate portion 37 to thus limit inward movement of the door 33. Formed integrally with the other end of the intermediate portion 7 is an outwardly extending flange 41 which extends alongside the outer surface of the vertical frame member and moves inwardly between the vertical frame member and the vertical casing 10 adjacent thereto, as shown in FIG. 3, whereby the keeper and gauge member 36 is anchored in place to prevent movement thereof during shipment and installation. A bendable flange 42 is provided at the end of the intermediate portion 37 carrying the flange 41 in position to move from the dotted line position shown in FIG. 2 to the solid line position shown in FIGS. 2 and 3. That is, the flange 42 is in the dotted line position prior to moving the door 33 into engagement with the flange 39. After the door 33 is moved into engagement with the flange 39, the flange 42 is bent to the position shown in FIG. 3 whereby the free end of the door 33 is held against swinging movement on its hinges 34. Preferably, the flanges 41 and 42 are provided by slitting the end portion of the sheet metal forming the member 36, as shown in FIG. 4.

To prevent separation of the lower ends of the vertical casing members 12 and 13 and the vertical frame members 18 and 19, the lower ends of the frame members 18 and 19 are connected to each other by a taut transverse member 43, which may be a flexible tie strip of material or the like. The tie strip 43 is preferably formed of a material that can be cut with a knife or chisel. This tie strip is not removed until after the door unit is installed. To prevent sagging of the free end of the door 33, a support bracket 44 is secured to the lower portion of the door by suitable means, such as staples 46. Transverse beads 47 are provided on the support bracket 44 in position to engage the inner surface of the vertical frame member 19, as shown in FIG. 4. The beads 47 also aid in holding the door 33 in parallel alignment with the vertical frame member 19. Suitable recesses 48 are provided in the support bracket 44 for receiving the staples 46, as shown in FIG. 2. The lower portion of the support bracket 44 is provided with transverse slits 49 and the portion of the bracket beneath the slits 49 is bent inwardly to provide inwardly extending flanges 51 which extend perpendicular to the remaining portion of the support bracket 44. The lower ends of the flanges 51 engage the transverse member 43 which connects the vertical support members 18 and 19, as shown in FIG. 4. The strip 43, in turn, is supported by the floor during installation. This prevents sagging of the free side of the door, thus maintaining the door in a square position relative to the door frame members.

From the foregoing description, the packaging and assembly of my improved door assembly 'will be readily understood. To package the assembly, the casing members 11, 12 and 13 are secured to the frame members 17, 18 and 19 by driving the nail-like members 21 through the door frame members and into the casing members at an angle of approximately 30 relative to the inner surface of the casing members, as shown in FIG. 3. Preferably, this is accomplished by an automatic nailing machine. A plurality of vertically spaced jamb brackets 24 are then inserted in the recesses 22 provided in the vertical frame members 19 whereby the anchor members 26 firmly secure the jamb brackets 24 in place for shipment. The jamb pins 28 are held in place on the jamb brackets 24 due to the fact that the detents 29 and 31 and the spring type detent 30 prevent separation of the jamb pin from the jamb bracket 24.

With the door frame members thus secure to the casing members, the door 33- is attached to the vertical frame member 18 which is directly opposite the vertical frame member 19 carrying the ends of the jamb brackets 24 having anchoring members 26 thereon. That is, the door 33 and the jamb bracket 24 .are attached to only one of the pair of door frame members whereby the other door frame member is attached at the time of installation of the door assembly. The keeper and gauge member 36 are secured in place at spaced intervals between the free edge at the top and side of the door 33 and the adjacent frame members by inserting the flanges 41 between the frame member and the adjacent casing member, as shown in FIG. 3. With the keeper and gauge members 36 thus installed, the inwardly extending flange 39 limits inward movement of the door 33 as it is moved to the position shown in FIG. 3. The transverse beads 38 engage the edge of the door 33 to thus maintain the same in true alignment relative to the door frame members. After the door is moved into the position shown in FIG. 3, the flanges 42 of the keeper and gauge members 36 are bent inwardly to the solid line position shown in FIGS. 2 and 3 whereby the door is held in place for shipment and installation.

Since the support bracket 44 is attached to the lower portion of the door, the flanges 51 engage the transverse strip 43 which, in turn is supported by the floor to thus prevent sagging of the free end of the door and further aid in maintaining the door in a square position relative to the door frame members. The door frame members and the casing members which form the other half of the door assembly are not secured to the jamb plates 24 during shipment but are secured in place at the time the door assembly is erected.

To install the door assembly, each half of the door as sembly is erected separately. The half containing the door is erected first by placing it in a centered and plumb position in the wall opening. In this position the casing members are nailed to the wall stud. The door is then released and opened only .enough to remove support bracket 44. When this is removed, the door is free to swing.

The next operation is to drive the jamb pins 28 into the wall stud 14 at .a depth to where each pin locks with its respective jamb plate 24. The door is then closed and the margin, or space between door and frame members, is checked. If, in driving the pins, the uniform margin is distorted at any location along the free edge of the door, it can be corrected by further driving the pin in or pulling it out a little with a hammer.

The next operation is to install the other half of the door unit by placing the frame members over and engaging the jamb plates 24. This half of the door unit is moved inward until the casings contact the wall stud 14. The casings are then nailed to the wall stud.

The next operation is to install the door stops, indicated in dotted lines at 52, against the gauge members. After the door stops are installed, all gauge members can be removed.

From the foregoing, it will be seen that I have devised an improved door assembly which permits the door to be hung in place on its door frame members prior to shipment and installation, without having to drive nails through the door frame members and the door for securing the door in place. By providing the keeper and guage members at spaced intervals between the door and the door frame members, the door is held against movement from a square position relative to the door frame members during shipment as well as during erection of the door assembly. Also, the inwardly extending flanges 39 carried by the keeper and gauge members position the door stops accurately relative to the door at the time the door stops are installed by merely positioning the door stop adjacent the flange 39. By providing the outwardly extending flanges 41 on the keeper and gauge members, the members are firmly secured in place during shipment and erection whereby there is no relative movement between the keeper and gauge members and the door. Furthermore, by providing the jamb plate 24 having the jamb pin 28 extending therethrough, the door frame members are secured firmly to each other and to the wall studs whereby the door frame members are held in a square position to permit free swinging movement of the door about its hinges.

While I have shown my invention in but one form, it will be obvious to those skilled in the art that it is not so limited, but is susceptible of various other changes and modifications without departing from the spirit thereof, and I desire, therefore, that only such limitations shall be placed threupon as are specifically set forth in the appended claims.

I claim:

1. In a door assembly adapted to be secured to wall studs:

(a) a pair of door casings each comprising a horizontal, top casing member and a pair of spaced apart vertical casing members adapted to be positioned at opposite sides of the wall studs,

(b) a pair of door frames each comprising a horizontal, top frame member and a pair of spaced apart vertical frame members disposed to extend parallel to and in spaced relation to each other with portions of the inner sides of adjacent vertical frame members at each side of the door assembly facing each other,

(0) means securing each door casing to its associated door frame,

(d) a jamlb plate of a predetermined length,

(e) there being oppositely disposed, aligned recesses of a predetermined depth in said inner sides of said vertical frame member which face each other for receiving opposite ends of said jamb plate so that said opposite ends engage said recesses to retain said adjacent vertical frame members in alignment with each other,

(f) there being a transverse opening through said jamb plate,

(g) a jamb pin extending through said opening in position to penetrate the wall stud so that said jamb plate and the vertical frame members connected thereto are secured to the wall stud,

(h) a detent on the portion of said jamb pin which is adapted to penetrate the wall stud extending outwardly of the surface of the jamb pin,

(i) a lateral projection adjacent the end of said jamb pin opposite the end thereof which penetrates the wall stud in position to engage said jamb plate upon driving said pin inwardly of the wall stud,

(j) a door hingedly connected along one edge to one vertical frame member of one door frame with the opposite edge of said door being adjacent the other vertical frame member of said one door frame, and

(k) means retaining said opposite edge of said door adjacent said other vertical frame member.

2. In a door assembly as defined in claim 1 in which the means retaining said opposite edge of the door adjacent said other vertical frame member comprises:

(a) a gauge member between said opposite edge of the door and said other vertical frame member having an effective thickness equal the desired clearance between said door and said other vertical frame member,

(b) a first flange at one end of said gauge member extending inwardly alongside said door generally perpendicular to said gauge member,

(c) a second flange at the other end of said gauge member extending outwardly alongside said other vertical frame member between said other vertical frame member and the vertical casing member adjacent thereto, and

(d) a bendable flange at said other end of the gauge member adapted to be bent from a position in which it lies in a common plane with said gauge member to a position in which it extends generally parallel to said first flange and alongside the opposite side of said door from said first flange.

3. In a door assembly as defined in claim 1 in which a transverse member connects the lower ends of said vertical frame members to limit outward movement thereof relative to each other and a door support bracket is attached to the lower portion of said opposite edge of the door and projects downwardly therefrom with inturned vertical flanges thereon engaging said transverse member to hold said door at a predetermined distance from said transverse member.

References Cited UNITED STATES PATENTS 2,720,308 10/1955 Howell 49-380 XR 2,730,773 1/ 1956 Logue 49-380 3,205,982 9/ 1965 Chimienti 49-380 XR 3,250,039 5/1966 Strutin 49-380 KENNETH DOWNEY, Primary Examiner. 

